Method of manufacturing pairs of spur gears

ABSTRACT

A method of producing pairs of mating spur gears by cutting tooth gaps with a rotating end cutter head, wherein, in order to manufacture the one spur gear, one of the elements--the spur gear or the end cutter head--carries out an arcuate or circular rolling movement about an axis which coincides or approximately coincides with the gear axis of the other gear, and the other gear is produced by a cutting-in depth or plunge cut operation without any rolling movement.

CROSS-REFERENCE TO RELATED CASE

The present application is a divisional of my copending, commonly assigned United States application, Ser. No. 729,351, filed Oct. 4, 1976 and now U.S. Pat. No. 4,183,703.

BACKGROUND OF THE INVENTION

The present invention relates to a new and improved method for manufacturing a pair of mating spur gears by cutting the tooth gaps with a rotating end cutter head or face mill cutter.

There are already known different methods for manufacturing pairs of spur gears, which have the drawback that both spur gears of a pair of gears must be produced by carrying out a generating process.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to provide a new and improved method of producing pairs of spur gears which is not associated with such drawback and renders possible the use of more efficient machines, by means of which, on the one hand, there can be improved the quality of the fabricated gears and, on the other hand, there can be shortened the manufacturing time.

Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the inventive method for producing a pair of mating spur gears is manifested by the features that for the fabrication of the one spur gear one of the elements--the spur gear or the end cutter head--carries out a circular rolling or generating movement about an axis which coincides or approximately coincides with the gear axis of the mating gear, and the mating gear is produced by a cutting-in depth or plunge cut operation without any generating or rolling movement.

There is already known a method for manufacturing arcuate-shaped teeth for bevel gears, wherein the flanks of the teeth of the one bevel gear are produced by means of an end cutter head which is moved in an arc corresponding to the curvature of the tooth. With this technique the one bevel gear is produced without any generating movement, whereas the other bevel gear is produced by a generating movement, and there is not generated or rolled along an imaginary crown gear rather along an imaginary bevel gear corresponding to the mating gear.

This heretofore known method for the production of bevel gears however cannot be used as such for the manufacture of spur gears, since it cannot be carried out upon the heretofore known gear cutting machines, since with such machines the cutter head is located upon a rolling cradle, the axis of which cutter head however cannot be positioned perpendicular to the axis of the rolling cradle, as would be necessary for this purpose.

The inventive gear cutting machine for carrying out the method of the invention is manifested by the features that one of the elements--the spur gear or the end cutter head--is rotatably mounted in a rolling cradle, the axis of the end cutter head is arranged perpendicular and the axis of the spur gear is arranged parallel to the axis of the rolling cradle, and one of both elements is displaceable in the axial direction and the other of such two elements is arranged to be pivotable relative to the other.

The pair of spur gears produced according to this method is manifested by the features that the teeth of the one spur gear are curved in cycloidal-shape in the lengthwise direction of the tooth and have an involute-shaped tooth depth profile, and the teeth of the mating gear are likewise curved in cycloidal-shape in the tooth lengthwise direction, but have a linear tooth depth profile.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

FIG. 1 illustrates a first exemplary embodiment of a gear cutting machine viewed from the front;

FIG. 2 is a side view of the gear cutting machine of FIG. 1;

FIG. 3 is a top plan view of the gear cutting machine of FIG. 1;

FIG. 4 is a schematic illustration of the geometric conditions prevailing between the spur gear and the cutting head;

FIG. 5 illustrates essentially to scale the tooth profiles of the spur gears;

FIGS. 6, 7, 8 and 9 illustrate in different views the respective position of the spur gear and cutter head for crown cutting;

FIG. 10 is a perspective view of the spur gear and cutter head;

FIG. 11 is a schematic illustration of a transmission employed with the inventive apparatus;

FIG. 12 illustrates a second exemplary embodiment of a gear cutting machine as viewed from the front;

FIG. 13 illustrates the modified gear cutting machine of FIG. 12 as viewed from the side; and

FIG. 14 illustrates a top plan view of the modified gear cutting machine of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Describing now the drawings, according to FIG. 1 the gear cutting machine, at which there is carried out the method of the invention for producing spur gear transmissions by way of example, will be seen to comprise a machine bed 10. At this machine bed 10 there is arranged, on the one hand, a rolling cradle stock 11 having a rolling or generating cradle 12 and, on the other hand, a headstock 13 at which there is rotatably mounted a cutter head or face mill cutter 14.

According to the showing of FIGS. 2 and 3, the rolling cradle 12 possesses a spindle 15 at which there is attached the spur gear 16 to be machined. At the cutter head 14 there are secured a number of cutters 17.

During the production of a spur gear 16 such rotates in the direction of the arrow A, the cutter head 14 in the direction of the arrow B and the rolling cradle 12, in the event a generating or rolling movement is needed, can rotate in the direction of the arrow C. For the cutting-in depth or plunge cut operation it is possible to displace the headstock 13 in the direction of the arrow D.

The rotational speed of the spur gear 16 and the cutter head 15 are coordinated in conventional manner to one another such that in each instance a cutter 17 or a group of cutters penetrate into a tooth gap or space of the spur gear 16 and the next cutter 17 or the next group of cutters penetrates into the next tooth gap or space of the spur gear 16 to be produced.

The spur gear 16 can be fabricated either by a pure generating or rolling movement without a cutting-in depth or plunge cut movement, or by a pure cutting-in depth movement without any generating movement. In order that there is produced a spur gear transmission it is necessary, with the here described gear cutting machine, that a spur gear be produced by a cutting-in depth operation and a mating gear by a generating or rolling movement.

The spacing a between the spur gear axis 18 and the cutter head axis 19 as well as the spacing b between the computation point 20 at the spur gear 16 and the cutter head axis 19 can be easily calculated, as will be more fully explained hereinafter in conjunction with FIG. 4.

According to the showing of FIG. 4 the cutter head 14, which has not been here illustrated, rotates about the cutter head axis 19, and in so doing a cutter 17 describes the circular arc 21. This cutter 17, in the showing of FIG. 4, is located at the previously mentioned computation point 20.

For the sake of simplicity it is assumed that penetrating through each tooth gap or space is a single cutter 17. The rotational speed n_(w) of the cutter head 14 and the rotational speed n_(r) of the spur gear 16 are then dependent upon the number of teeth z of the spur gear 16 and the number of cutters z_(w). There will be seen from FIG. 4 the following relationship: ##EQU1##

Further, if it is assumed that the spur gear 16 stands still, and that the cutter head 14 carries out a generating or rolling movement upon a plane 23 with a rolling wheel 22 of the radius ##EQU2## then it is clear that there are formed cycloidal-shaped curved longitudinal tooth lines.

The pitch circle diameter d_(o) of the spur gear 16 (FIG. 3) is determined from the teeth number z, the normal plane pitch m_(n) and the cosine of the angle of skew β_(m). Thus there exists the relationship: ##EQU3##

The generating circle radius ##EQU4## is dependent upon the cutter number z_(w) and the normal plane pitch m_(n). There exists the relationship: ##EQU5##

Finally, there can be derived from the radius r_(w) of the cutter head 14 and the generating circle radius E_(b) the angle δ_(w) as follows: ##EQU6##

The mentioned distances a and b now are determined from the radius r_(w) of the cutter head and its angle of inclination ω relative to the spur gear axis 18, namely:

    a=r.sub.w sin ω

    b=r.sub.w cos ω

wherein

    ω=90°-β.sub.m +δ.sub.w

The angle of skew β changes as a function of the spacing a_(x) from the tooth center. Since it can be significant to know the manner in which the spiral angle varies from the center of the tooth towards the outside, below there are given the most important equations for calculating the angle of skew. ##EQU7##

In FIG. 5 there are illustrated to scale a number of longitudinal tooth lines of spur gears. Apart from the angle of skew β_(m) there is indicated the number of cutters z_(w) and the cutter radius r_(w). Thus, the relationship: "β_(m) =0°; 5-39" means that β_(m) =0°, z_(w) =5 and r_(w) =39 mm.

As already mentioned, with the here described machine it is necessary that a spur gear is produced by a cutting-in depth or plunger cut operation and that the mating gear is produced by a generating operation, but if however both spur gears are to be produced with a generating technique, then, the rolling cradle must be replaced by an apparatus which allows for a linear generating or rolling movement. For an exact roll-off or generating movement the spacing e between the spur gear axis 18 and the rolling cradle axis 24 must be equal to the sum of the pitch circle radii of both spur gears in meshing engagement with one another. If therefore the pitch circle radius of both spur gears is designated by d1/2 and d2/2, then: ##EQU8##

This rolling or generating movement has been illustrated in FIG. 1. Whereas the cutter head 14 and the spur gear 16 continuously rotate about their own axes 19 and 18, respectively, the rolling cradle 12 rotates about the rolling cradle axis 24. The spur gear 16 thus moves out of the position 16' into the position 16", and the spur gear axis 18 describes an arc of the angle γ. During this movement, the spur gear 16 is rolled-off or generated relative to the cutters 17 of the cutter head 14. It can be thus imagined that the cutter 17 constitutes a tooth of the mating gear 25, the axis of which coincides with the rolling cradle axis 24. Since the cutter 17 possesses straight flanks, afterwards the mating gear 25 also must have straight flanks.

With this machine the size of the spur gears 16 which can be produced thereat, are determined by the spacing e=(d1+d2/2) between the spur gear axis 18 and the rolling cradle axis 24 as well as by the spacing a=r_(w) sin ω, wherein r₂ =cutter head radius and ω=90°-β_(m) +δ_(w), and wherein e is essentially dependent upon the size of the rolling cradle 12.

The described method for fabricating spur gears also makes it possible to produce a longitudinal crown at the teeth. This crown can be infinitely varied by changing the size of the inclination of the cutter head. The longitudinal crown is preferably produced at the gear having the straight tooth depth profile. In order to obtain a longitudinal crown-spur gear transmission or gearing, it is necessary, on the one hand, to adjust the angle between the spur gear axis 18 and the cutter head axis 19 and, on the other hand, to adjust the spacing a between the spur gear axis 18 and the stationary axis 24 in accordance with the desired crown.

As will be realized from the following calculations, the aforementioned spacing a must be reduced by an amount a₂₀. The cutter head axis 19 furthermore must be rocked through an angle φ₁₁ out of the plane which is disposed perpendicular to the spur gear axis 18 and the rolling cradle axis 24.

As will be apparent from FIGS. 6-9, for the longitudinal crown the cutter head axis 19 must be rocked in a plane perpendicular to the tangent at the point of contact 20 (FIG. 4) through the angle χ (FIG. 6). It is necessary to pivot the cutter head axis 19 through the angle φ₁₀ (FIG. 8) with respect to the horizontal plane in which there are located the spur gear axis 18 and the rolling cradle axis 24. However, instead of pivoting through both of these pivot angles χ and φ₁₀ it is possible to rock the cutter head axis 19 in the mentioned horizontal plane about the mentioned angle φ₁₁ and to displace such by the mentioned value a₂₀ towards the spur gear axis 19.

According to FIG. 6 there is present the relationship: ##EQU9##

According to FIG. 7 there is present the relationship: ##EQU10##

According to FIG. 8 there is present the relationship: ##EQU11##

According to FIG. 9 there is present the relationship: ##EQU12##

By substitution there is derived: ##EQU13##

For purposes of clarification there have been illustrated in perspective view in FIG. 10 the cutter head 14 and the spur gear 16 and there have been plotted the necessary corrections φ₁₁ and a₂₀. The angle φ₁₁ can be adjusted either by rocking the cutter head axis 19 or by rocking the spur gear axis 18. Equally, there can be displaced either the cutter head axis 19 or the spur gear axis 18 to the desired spacing a--a₂₀. The different displacement possibilities will be apparent from the showing of FIGS. 1-3. The cradle 12 together with the support or cradle stock 11 is pivotably mounted upon the machine bed 10. The cutter head axis 19 is vertically displaceable in the housing 13.

The drive of the rolling cradle 12, spur gear 16 and cutter head 14 will be apparent from the showing of FIG. 11.

According to FIG. 11 there is attached to the rolling cradle 12 a worm gear 30 which meshes with a worm 31. The worm 31 is secured to a shaft 32 which is provided at its other end with a worm gear 33. The worm gear 33 meshes with a further worm 34. This worm 34 is connected through the agency of four spur gears 35, 36, 37 and 38 via six change-speed gears 39, 40, 41, 42, 43 and 44 in driving relationship with a spur gear 45. This spur gear 45 meshes with a toothed rim 46 which is attached to a housing 47 of a differential transmission or gearing. In this housing 47 there are located two sun gears 48 and 49 as well as two planetary gears 50 and 51. The sun gear 48 is connected by a shaft 52 with a spur gear 53. The spur gear 53 is drivingly connected by means of the spur gears 54, 55 and 56 with a shaft 57 mounted at the rolling cradle axis 24. The shaft 57 is drivingly connected via the pairs of bevel gears 58, 59 and 60, 61 with a spur gear 62. The spur gear 62 meshes with a disk 63 internally provided with teeth, and which disk is secured to the spindle shaft 15 at which there is seated the spur gear 16 to be machined. The other sun gear 49 is drivingly connected by means of the shaft 64, the speed gears 65, 66, the shaft 67, the bevel gears 68 and 69, and the shaft 70 with an index gearing. This index gearing possesses six spur gears 71, 72; 73, 74; 75, 76 and is drivingly connected with a spur gear 77. The spur gear 77 meshes with a spur gear 78 arranged at the cutter head axis 19. The spur gear 78 is rigidly connected by means of a shaft 79 with the cutter head 14. Provided for the drive of the rolling cradle 12 is a first electric motor 80 which drives the spur gear 38, and for the drive of the spur gear 16 which is to be produced and the cutter head 14 there is provided a second electric motor 81 which drives the spur gear 54.

Instead of, as described, using the rolling cradle 12 for the rolling or generating movement during the production of the one spur gear 16 and to produce the other spur gear 25 by a cutting-in depth operation, both spur gears can be produced by a rolling or generating operation. For this purpose the rotating cutter head 14 is shifted in the direction of the arrow E. The rolling cradle then must not rotate, the cradle drive is therefore disconnected.

According to FIG. 12, the second embodiment of gear cutting machine for carrying out the inventive method comprises a machine bed 82. Arranged upon this machine bed 82 is, on the one hand, a cradle stock or support 83 with a rolling cradle 84 and, on the other hand, a headstock 85 upon which there is rotatably mounted the spur gear 86 to be fabricated. According to FIGS. 13 and 14 the rolling cradle 84 possesses a spindle housing 87 which carries a cutter head 88. At the cutter head 88 there are attached a number of cutters or knives 89. Just as was the case for the gear cutting machine according to the first exemplary embodiment (FIGS. 1-3), with the gear cutting machine according to the second exemplary embodiment (FIGS. 12-14) the cutter head axis 90 is arranged perpendicular to the rolling cradle axis 91 and the spur gear axis 92 is parallel to the rolling cradle axis 91.

During the production of the spur gear 86 such rotates exclusively in the direction of the arrow A about its stationary spur gear axis 92. The cutter head 88 rotates in the direction of the arrow B and the rolling cradle 84, to the extent that a rolling or generating movement is necessary, rotates in the direction of the arrow C.

For the cutting-in depth movement it is only necessary to displace the headstock 85 with the spur gear 86 in the direction of the arrow D.

The rotational speeds of the spur gear 86 and the cutter head 88, also with this exemplary embodiment of gear cutting machine, are coordinated to one another in conventional manner in such a way that in each instance a cutter 89 or a group of cutters penetrates into a tooth gap of the spur gear 86 and the next cutter 89 or the next group of cutters penetrates into the next tooth gap of the spur gear 86 to be produced.

In order to improve the bearing area configuration during the rolling or generating movement the spacing e between the spur gear axis 18 and the rolling cradle axis 24 can be increased or reduced. Due to this change in the spacing e there is formed over the angle of skew β_(m) a tooth bending or torsion, so that in the case of crown (camber)-bearing teeth there are realized bearing area corrections ensuring for greater shifting capability and increased quiet running.

While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY, 

What I claim is:
 1. A method of manufacturing a pair of mating spur gear elements by cutting out tooth gaps with an end cutter head element wherein one of two elements--one of said mating spur gear elements having an axis and the end cutter head element having an axis--is mounted on a rolling cradle having an axis, comprising the steps of:(I) imparting to the one of said two elements, mounted on the rolling cradle, an arcuate-shaped generating movement, (II) (a) arranging and maintaining the axis of the one mating spur gear element being cut parallel to the axis of the rolling cradle, and (II) (b) simultaneously arranging and maintaining the axis of the end cutter head element substantially perpendicular to the axis of the rolling cradle during said arcuate-shaped generating movement, (III) moving one of the axis of the one mating spur gear element and the axis of the end cutter head element relative to the other axis through said arcuate-shaped generating movement around the axis of the rolling cradle, (IV) coinciding the center of the arcuate-shaped generating movement with the center of the other mating spur gear element to be produced, and (V) fabricating the other mating spur gear element by a plunge cut operation without any generating movement to produce gear teeth having a straight tooth depth profile in a radial direction.
 2. The method as defined in claim 1, including the step of imparting the arcuate-shaped generating movement to one of the pair of mating spur gear elements.
 3. The method as defined in claim 1, including the step of imparting the arcuate-shape generating movement to the end cutter head element.
 4. The method as defined in claim 1, including the step of manufacturing both spur gear elements of the pair of mating spur gears elements in a continuous partial operation with cycloidal-shaped teeth curved in the lengthwise direction of the teeth.
 5. The method as defined in claim 4, including the step of cutting-out the tooth gaps by rotating one spur gear element of the pair of mating spur gears elements about its axis and, for the generating movement, moving the spur gear axis along a circular arc.
 6. The method as defined in claim 5, further including the step of rotating the other mating spur gear element, being fabricated by the plunge cut operation, about a stationary axis, and displacing the end cutter head element in a radial direction of the stationary axis at a distance spaced from said other mating spur gear element.
 7. The method as defined in claim 6, further including the step of crown cutting the teeth of the one mating spur gear element by changing spacing between the stationary axis and the axis of the one mating spur gear element and also by changing the angle between the axis of the one mating spur gear element and the end cutter head element by an amount corresponding to the required camber of the teeth.
 8. The method as defined in claim 4, further including for cutting-out the tooth gaps and for producing the one spur gear element, the step of having the end cutter head element carry out about an axis, which coincides with an axis of the other mating spur gear element, a circular arc-shaped generating movement.
 9. The method as defined in claim 8, further including the step of rotating the other mating spur gear element, being fabricated by the plunge cut operation, about a stationary axis, and displacing the end cutter head element in a radial direction of the stationary axis at a distance spaced from said other mating spur gear element.
 10. The method as defined in claim 9, further including the step of crown cutting the teeth of the one mating spur gear element by changing spacing between the stationary axis and the axis of the one mating spur gear element and also by changing the angle between the axis of the one mating spur gear element and the cutter head element by an amount corresponding to the required camber of the teeth. 